Surgical stapling instrument incorporating an electroactive polymer actuated firing bar track through an articulation joint

ABSTRACT

A surgical stapling instrument particularly suited to endoscopic use articulates an end effector (e.g., stapling and severing) that is actuated by a firing bar. An articulation mechanism in an elongate shaft incorporates electrically actuated polymer (EAP) actuators that laterally support the firing bar so that the firing bar is sufficiently constrained to avoid a blow-out, yet is guided without excessive friction and binding. Thereby, effective, consistent firing is accomplished without an undue increase in firing force required when the end effector is articulated.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application Ser.No. 60/591,694, entitled “SURGICAL INSTRUMENT INCORPORATING ANELECTRICALLY ACTUATED ARTICULATION MECHANISM” to Shelton IV, filed 28Jul. 2004.

This application is a continuation-in-part of U.S. patent applicationSer. No. 10/615,971, entitled “SURGICAL STAPLING INSTRUMENT HAVINGARTICULATION JOINT SUPPORT PLATES FOR SUPPORTING A FIRING BAR” to Wales,et al., filed 9 Jul. 2003, which is hereby incorporated by reference inits entirety.

FIELD OF THE INVENTION

The present invention relates in general to surgical instruments thatare suitable for endoscopically inserting an end effector (e.g.,endocutter, grasper, cutter, staplers, clip applier, access device,drug/gene therapy delivery device, and an energy device usingultrasound, RF, laser, etc.) to a surgical site, and more particularlyto such surgical instruments with an articulating shaft.

BACKGROUND OF THE INVENTION

Endoscopic surgical instruments are often preferred over traditionalopen surgical devices since a smaller incision tends to reduce thepost-operative recovery time and complications. Consequently,significant development has gone into a range of endoscopic surgicalinstruments that are suitable for precise placement of a distal endeffector at a desired surgical site through a cannula of a trocar. Thesedistal end effectors engage the tissue in a number of ways to achieve adiagnostic or therapeutic effect (e.g., endocutter, grasper, cutter,staplers, clip applier, access device, drug/gene therapy deliverydevice, and energy device using ultrasound, RF, laser, etc.).

Positioning the end effector is constrained by the trocar. Generallythese endoscopic surgical instruments include a long shaft between theend effector and a handle portion manipulated by the clinician. Thislong shaft enables insertion to a desired depth and rotation about thelongitudinal axis of the shaft, thereby positioning the end effector toa degree. With judicious placement of the trocar and use of graspers,for instance, through another trocar, often this amount of positioningis sufficient. Surgical stapling and severing instruments, such asdescribed in U.S. Pat. No. 5,465,895, are an example of an endoscopicsurgical instrument that successfully positions an end effector byinsertion and rotation.

More recently, U.S. pat. Ser. No. 10/443,617, “SURGICAL STAPLINGINSTRUMENT INCORPORATING AN E-BEAM FIRING MECHANISM” to Shelton et al.,filed on 20 May 2003, which is hereby incorporated by reference in itsentirety, describes an improved “E-beam” firing bar for severing tissueand actuating staples. Some of the additional advantages includeaffirmatively spacing the jaws of the end effector, or more specificallya staple applying assembly, even if slightly too much or too littletissue is clamped for optimal staple formation. Moreover, the E-beamfiring bar engages the end effector and staple cartridge in a way thatenables several beneficial lockouts to be incorporated.

Depending upon the nature of the operation, it may be desirable tofurther adjust the positioning of the end effector of an endoscopicsurgical instrument. In particular, it is often desirable to orient theend effector at an axis transverse to the longitudinal axis of the shaftof the instrument. The transverse movement of the end effector relativeto the instrument shaft is conventionally refeffed to as “articulation”.This is typically accomplished by a pivot (or articulation) joint beingplaced in the extended shaft just proximal to the staple applyingassembly. This allows the surgeon to articulate the staple applyingassembly remotely to either side for better surgical placement of thestaple lines and easier tissue manipulation and orientation. Thisarticulated positioning permits the clinician to more easily engagetissue in some instances, such as behind an organ. In addition,articulated positioning advantageously allows an endoscope to bepositioned behind the end effector without being blocked by theinstrument shaft.

Approaches to articulating a surgical stapling and severing instrumenttend to be complicated by integrating control of the articulation alongwith the control of closing the end effector to clamp tissue and firethe end effector (i.e., stapling and severing) within the small diameterconstraints of an endoscopic instrument. Generally, the three controlmotions are all transferred through the shaft as longitudinaltranslations. For instance, U.S. Pat. No. 5,673,840 discloses anaccordion-like articulation mechanism (“flex-neck”) that is articulatedby selectively drawing back one of two connecting rods through theimplement shaft, each rod offset respectively on opposite sides of theshaft centerline. The connecting rods ratchet through a series ofdiscrete positions.

In U.S. patent application Ser. No. 10/615,971, support plates aredescribed that guide a firing bar through a pivoting articulation joint.Resilient or spring features at one or both ends advantageouslycompensate for the change in radial distance between the inner and outersupport plates, thus maintaining a spacing therebetween to avoidbinding. Thus, blowouts of the firing bar are avoided withoutintroducing performance degradation, such as increasing the forcerequired to actuate the firing mechanism.

While these generally-known approaches successfully support the firingbar through an articulation joint for a surgical stapling and severinginstrument, it is desirable to further enhance their performance.

Consequently, a significant need exists for an improved articulatingsurgical instrument that supports a firing bar through an articulationjoint.

BRIEF SUMMARY OF THE INVENTION

The invention overcomes the above-noted and other deficiencies of theprior art by providing a surgical instrument with an articulating shaftattached between a handle and an end effector. A pair of electroactivepolymer (EAP) support members are disposed in an articulation joint ofthe shaft and are responsive to an electrical signal passed through theshaft. Each member is aligned with and laterally offset from thelongitudinal axis of the articulation joint. Activating a selective EAPsupport member effects a longitudinal dimensional change to assistarticulation.

In one aspect of the invention, a surgical instrument includes an endeffector that is actuated by a firing bar that translates within theelongate shaft. The EAP support resides on each lateral side of thefiring bar as it transitions through an articulation joint. By changingdimensionally the change in radius of rotation for the EAP supportmember on the inside of the articulation bend as compared to the EAPsupport member on the outside, spacing is preserved to effectively guidethe firing bar without binding.

In another aspect of the invention, an articulating shaft of a surgicalinstrument is supported in articulating by having a pair of laterallyoffset, longitudinally aligned EAP support members that have one endlongitudinally constrained and the other end slidingly received. The EAPsupport members are configured to bend when activated to assist inarticulating.

In another aspect of the invention, an articulating shaft of a surgicalinstrument is supported in articulating by having a pair of laterallyoffset, longitudinally aligned EAP support members that have both endslongitudinally constrained respectively in the proximal and distal endsof the articulation joint. The EAP support members are confirmed tochange in longitudinal length when activated to assist in articulation.

These and other objects and advantages of the present invention shall bemade apparent from the accompanying drawings and the descriptionthereof.

DESCRIPTION OF THE FIGURES

The accompanying drawings, which are incorporated in and constitute apart of this specification, illustrate embodiments of the invention,and, together with the general description of the invention given above,and the detailed description of the embodiments given below, serve toexplain the principles of the present invention.

FIG. 1 is a rear perspective view of an endoscopic surgical staplinginstrument for surgical stapling and severing in an open, unarticulatedstate.

FIG. 2 is a perspective view of a laminate Electroactive Polymer (EAP)composite.

FIG. 3 is a perspective view of an EAP plate actuator formed from astack formed from an adhesively affixed plurality of laminate EAPcomposites of FIG. 2.

FIG. 4 is a perspective view of a cutaway along a longitudinal axis of acontracting EAP fiber actuator.

FIG. 5 is a front view in elevation taken in cross section along lines5-5 of the contracting EAP fiber actuator of FIG. 4.

FIG. 6 is a front right perspective view of an EAP actuated articulationjoint for the surgical instrument of FIG. 1 with a flexible closuresleeve assembly, a pivoting frame assembly and a closed staple applyingassembly.

FIG. 7 is a front right perspective view of the EAP actuatedarticulation joint and closed staple applying assembly of FIG. 6 with aflexible closure sleeve assembly removed and a single pivot frameassembly partially exploded.

FIG. 8 is a front right exploded perspective view of the EAP actuatedarticulation joint and staple applying assembly of FIG. 6.

FIG. 9 is a detail view of the exploded single pivot frame assemblyincluding EAP fiber actuators of FIG. 7.

FIG. 10 is a right side view in elevation taken in cross section alonglines 10-10 of FIG. 6 through a pivot axis of the EAP actuatedarticulation joint and looking right to see a pair of EAP fiberactuators.

FIG. 11 is a top view taken in cross section along lines 11-11 of FIG.11 through a longitudinal axis of the EAP actuated articulation jointlooking down to see a lower moment arm and lower EAP fiber actuators.

FIG. 12 is a front view in elevation taken in cross section along lines12-12 of FIG. 10 along the lateral EAP fiber actuators.

FIG. 13 is a top view of the EAP actuated articulation joint of FIG. 11with the right upper and lower EAP fiber actuators contracted toarticulate the staple applying assembly to the left.

FIG. 14 is a front right perspective view of an additional alternativeEAP actuated articulation joint that includes a double pivot closuresleeve assembly in a proximal position opening of the anvil of the endeffector.

FIG. 15 is a front right exploded view of the additional alternative EAPactuated articulation joint of FIG. 14 including the double pivotclosure sleeve assembly and a single pivot frame assembly.

FIG. 16 is a right side view in elevation of the alternative EAPactuated articulation joint taken in cross section along lines 16-16 ofFIG. 14 with firing components included.

FIG. 17 is a top view of the alternative EAP actuated articulation jointin an unarticulated condition taken in cross section along lines 17-17of FIG. 14.

FIG. 18 is a top view of the alternative EAP actuated articulation jointin a leftward articulated condition taken in cross section along lines17-17 of FIG. 14.

FIG. 19 is yet another alternative EAP actuated articulation joint in aslightly articulated condition with a contracting EAP fiber actuatorpositioned to straighten the joint.

FIG. 20 is a right front perspective view of a partially exploded singlepivot articulation joint that advantageously includes an EAParticulation locking mechanism that is biased to be normally locked.

FIG. 21 is a right front perspective view in detail of a proximalportion of the EAP articulation locking mechanism in a proximal frameground of the single pivot articulation joint.

FIG. 22 is a top view of the single pivot articulation joint of FIG. 20.

FIG. 23 is a right side view in elevation of the single pivotarticulation joint of FIG. 22 taken in cross section along alongitudinal centerline of lines 23-23.

FIG. 24 is a top view of the single pivot articulation joint of FIG. 23taken in cross section along lines 24-24 to show a gear segment on anupper pivot tang locked by the EAP articulation locking mechanism in anunarticulated condition.

FIG. 25 is a top view of the single pivot articulation joint of FIG. 23taken in cross section along a centerline of lines 24-24 looking downupon a lower pivot tab of a proximal frame ground that is partiallyarticulating an end effector to the left while the EAP articulationlocking mechanism is activated to an unlocked condition.

FIG. 26 is a front view in elevation of a distal frame ground of thesingle pivot articulation mechanism of FIG. 24 taken in cross sectionalong lines 26-26 depicting attachment of EAP fiber actuators thatarticulate the joint.

FIG. 27 is a front view in elevation of the proximal frame ground of thesingle pivot articulation joint of FIG. 24 taken in cross section alonglines 27-27 to expose EAP stack actuators and locking pins of the EAPactuated locking mechanisms.

FIG. 28 is a top view taken in cross section along an interface betweenan upper pivot tang of a distal frame ground and an upper pivot tab of aproximal frame ground of a single pivot articulation joint withlengthened EAP fiber actuators acting upon rounded moment arms incombination with the EAP articulation locking mechanism.

FIG. 29 is a front view in elevation taken generally in cross sectionthrough the proximal frame ground and EAP articulation locking mechanismbut also showing more distally viewed moment arms and lengthened EAPfiber actuators connected thereto.

FIG. 30 is a top view of a single pivot articulation joint taken incross section along a top surface of an upper pivot tab of a proximalframe ground to illustrate expansive EAP stack actuators employedagainst a moment arm distally attached to the upper pivot tab to effectarticulation used in conjunction with the normally locked EAParticulation locking mechanism activated in preparation forarticulation.

FIG. 31 is a front view in elevation of the single pivot articulationjoint of FIG. 30 taken in cross section through upper and lower tip pinsfrom the moment arms and through the EAP stack actuators.

FIG. 32 is a top view of the single pivot articulation joint of FIG. 30taken in cross section along a top surface of the upper pivot tab of theproximal frame ground after articulation of the distal frame ground tothe left but before deenergizing the EAP articulation locking mechanismto effect articulation locking.

FIG. 33 is a front view in elevation of the single pivot articulationjoint of FIG. 31 taken in cross section through the upper and lower tippins from the moment arms and through the expanded left and compressedright EAP stack actuators.

FIG. 34 is a right side view in elevation of a surgical instrument witha closure sleeve assembly cut away to expose an EAP actuatedarticulation mechanism that articulates a flexible articulating frameground.

FIG. 35 is a top view of the surgical instrument of FIG. 34 articulatingto the left.

FIG. 36 is a front right perspective view of the articulating frameground of FIG. 34 that incorporates EAP plate actuators and lockingstrips.

FIG. 37 is a top view of the articulating frame ground of FIG. 34 in aleft articulated state with a left EAP locking strip shown in phantom inan unlocked actuated state and a locked relaxed state.

FIG. 38 is a top view of the articulating frame ground of FIG. 34 in aleft articulated state taken in cross section through the EAP plateactuators and EAP locking strips.

FIG. 39 is a front view in elevation of the articulating frame ground ofFIG. 37 taken in cross section through lines 39-39 through the lateralguide pins.

FIG. 40 is a top view of an alternate articulating frame ground taken incross section through a plurality of EAP rib spreader actuators.

FIG. 41 is a right perspective partially exploded view of an additionalalternative articulating frame ground having a plurality of EAP fiberactuators.

FIG. 42 is a front view in elevation of the additional alternativearticulating frame ground of FIG. 41 taken in cross section along lines42-42.

FIG. 43 is a top view taken in longitudinal cross section of a firingbar passing through an articulation joint of a surgical instrument withthe firing bar advantageously laterally guided by support plates ofinwardly actuated EAP plate actuators with one sliding end.

FIG. 44 is a top view taken in longitudinal cross section of the firingbar passing through an articulated articulation joint of the surgicalinstrument of FIG. 43.

FIG. 45 is a top view taken in longitudinal cross section of a firingbar passing through an articulated articulation joint of a surgicalinstrument with the firing bar advantageously laterally guided bysupport plates of outwardly actuated EAP plate actuators with onesliding end.

FIG. 46 is a top view taken in longitudinal cross section of a firingbar passing through an articulation joint of a surgical instrument withthe firing bar advantageously laterally guided by outwardly actuated EAPsupport plates having constrained but longitudinally floating hookedends.

FIG. 47 is a top view taken in longitudinal cross section of a firingbar passing through an articulation joint of a surgical instrument withthe firing bar advantageously laterally guided by outwardly actuated EAPsupport plates, each having one fixed hooked end and one end springedlylongitudinally constrained.

FIG. 48 is a top view taken in longitudinal cross section of a firingbar passing through an articulation joint of a surgical instrument withthe firing bar advantageously laterally guided by outwardly actuated EAPsupport plates with each having both ends springedly longitudinallyconstrained.

FIG. 49 is a top view of a flexible articulation joint incorporating EAPsupport plates of FIG. 45 or 46.

FIG. 50 is a front view in elevation of the flexible articulation jointof FIG. 49 taken through lines 4949.

FIG. 51 is a top view of the flexible articulation joint of FIG. 49articulated to the left.

FIG. 52 is a front right perspective view of a flexible articulationjoint incorporating EAP support plates of FIG. 45 or 46 and alsoincluding left and right EAP plate articulation actuators.

FIG. 53 is a top view of an articulation joint taken in cross sectionthrough a longitudinal axis with a pair of support plates having oneoutwardly bent end fixed on one side of the joint and having anotheroutwardly bent end resiliently held within a frame recess betweenopposing EAP stack actuators.

FIG. 54 is a top view of an articulation joint taken in cross sectionthrough a longitudinal axis with a pair of support plates having bothoutwardly bent ends resiliently held within respective frame recessesbetween opposing EAP stack actuators.

DETAILED DESCRIPTION OF THE INVENTION

Overview of Articulating Shaft.

In FIG. 1, a surgical instrument, depicted as a surgical severing andstapling instrument 10, has at its distal end an end effector of astaple applying assembly 12, spaced apart from a handle 14 by anelongate shaft 16. The staple applying assembly 12 includes a staplechannel 18 for receiving a replaceable staple cartridge 20. Pivotallyattached to the staple channel 18 is an anvil 22 that clamps tissueagainst the staple cartridge 20 for stapling and severing. When thestaple applying assembly 12 is closed, its cross sectional area, as wellas the elongate shaft 16, are suitable for insertion through a smallsurgical opening, such as through a cannula of a trocar (not shown).

Correct placement and orientation of the staple applying assembly 12 isfacilitated by controls on the handle 14. In particular, a rotation knob30 causes rotation of the shaft 16 about its longitudinal axis, andhence rotation of the staple applying assembly 12. Additionalpositioning is enabled at an articulation joint 32 in the shaft 16 thatpivots the staple applying assembly 12 in an arc from the longitudinalaxis of the shaft 16, thereby allowing placement behind an organ orallowing other instruments such as an endoscope (not shown) to beoriented behind the staple applying assembly 12. This articulation isadvantageously effected by an articulation control switch 34 on thehandle 14 that transmits an electrical signal to the articulation joint32 to an Electroactive Polymer (EAP) actuator 36, powered by an EAPcontroller and power supply 38 contained within the handle 14.

Once positioned with tissue in the staple applying assembly 12, asurgeon closes the anvil 22 by drawing a closure trigger 40 proximallytoward a pistol grip 42. Once clamped thus, the surgeon may grasp a moredistally presented firing trigger 44, drawing it back to effect firingof the staple applying assembly 12, which in some applications isachieved in one single firing stroke and in other applications bymultiple firing strokes. Firing accomplishes simultaneously stapling ofat least two rows of staples while severing the tissue therebetween.

Retraction of the firing components may be automatically initiated uponfull travel. Alternatively, a retraction lever 46 may be drawn aft toeffect retraction. With the firing components retracted, the stapleapplying assembly 12 may be unclamped and opened by the surgeon slightlydrawing the closure trigger 40 aft toward the pistol grip 42 anddepressing a closure release button 48 and then releasing the closuretrigger 40, thereby releasing the two stapled ends of severed tissuefrom the staple applying assembly 12.

It should be appreciated that herein spatial terms such as vertical,horizontal, etc. are given with reference to the figures assuming thatthe longitudinal axis of the surgical instrument 10 is horizontal withthe anvil 22 of the staple applying assembly 12 aligned vertically ontop and the triggers 40, 44 aligned vertically on the bottom of thehandle 14. However, in actual practice the surgical instrument 10 may beoriented at various angles and as such these spatial terms are usedrelative to the surgical instrument 10 itself. Further, proximal is usedto denote a perspective of a clinician who is behind the handle 14 whoplaces the end effector 12 distal, away from himself.

Handle.

In FIG. 1, the staple applying assembly 12 accomplishes the functions ofclamping onto tissue, driving staples and severing tissue by twodistinct motions transferred longitudinally down the shaft 16 over ashaft frame (not shown in FIG. 1 but described below regarding FIG. 7).This shaft frame assembly is proximally attached to the handle 14 andcoupled for rotation with the rotation knob 30. An illustrativemulti-stroke handle 14 for the surgical stapling and severing instrument10 of FIG. 1 is described in greater detail in the co-pending andco-owned U.S. patent applications entitled “SURGICAL STAPLING INSTRUMENTINCORPORATING A MULTISTROKE FIRING POSITION INDICATOR AND RETRACTIONMECHANISM” to Swayze and Shelton, Ser. No. 10/674,026, and entitled“SURGICAL STAPLING INSTRUMENT INCORPORATING A MULTI-STROKE FIRINGMECHANISM WITH AUTOMATIC END OF FIRING TRAVEL RETRACTION”, Ser. No.______, filed on Feb. 7, 2005 to Kevin R. Doll, Jeffrey S. Swayze,Frederick E. Shelton IV, Douglas B. Hoffman, and Michael E. Setser, thedisclosures of which are hereby incorporated by reference in theirentirety, with additional features and variations as described herein.

While a multi-stroke handle 14 advantageously supports applications withhigh firing forces over a long distance, applications consistent withthe present invention may incorporate a single firing stroke, such asdescribed in co-pending and commonly owned U.S. patent application“SURGICAL STAPLING INSTRUMENT HAVING SEPARATE DISTINCT CLOSING ANDFIRING SYSTEMS” to Frederick E. Shelton IV, Michael E. Setser, and BrianJ. Hemmelgam, Ser. No. 10/441,632, the disclosure of which is herebyincorporated by reference in its entirety.

Electroactive Polymers.

Electroactive polymers (EAPs) are a set of conductive doped polymersthat change shape when an electrical voltage is applied. In essence, theconductive polymer is paired to some form of ionic fluid or gel andelectrodes. Flow of the ions from the fluid/gel into or out of theconductive polymer is induced by the voltage potential applied and thisflow induces the shape change of the polymer. The voltage potentialranges from 1V to 4 kV depending on the polymer and ionic fluid used.Some of the EAPs contract when voltage is applied and some expand. TheEAPs may be paired to mechanical means such as springs or flexibleplates to change the effect that is caused when the voltage is applied.

There are two basic types of electroactive polymers and multipleconfigurations of each type. The two basic types are a fiber bundle anda laminate version. The fiber bundle consists of fibers around 30-50microns. These fibers may be woven into a bundle much like textiles andare often called EAP yarn because of this. This type of EAP contractswhen voltage is applied. The electrodes are usually a central wire coreand a conductive outer sheath, which also serves to contain the ionicfluid that surrounds the fiber bundles. An example of a commerciallyavailable fiber EAP material is manufactured by Santa Fe Science andTechnology, and is sold as PANION™ fiber and is described in U.S. Pat.No. 6,667,825, which is hereby incorporated by reference in itsentirety.

The other type is a laminate structure, which consists of a layer of EAPpolymer, a layer of ionic gel and two flexible plates that are attachedto either side of the laminate. When a voltage is applied, the squarelaminate plate expands in one direction and contracts in theperpendicular direction. Artificial Muscle Inc., a division of SRILaboratories, manufactures an example of a commercially availablelaminate (plate) EAP material. Plate EAP material is also available fromEAMEX of Japan and is referred to as thin film EAP. It should be notedthat EAPs do not change volume when energized; they merely expand orcontract in one direction while doing the opposite in the transversedirection. The laminate version may be used in its basic form by placingone side against a rigid structure and using the other much like apiston. It may also be adhered to either side of a flexible plate. Whenone side of the flexible plate EAP is energized, it expands, flexing theplate in the opposite direction. This allows the plate to be flexedeither direction depending on which side is energized.

An EAP actuator usually consists of numerous layers or fibers bundledtogether to work in cooperation. The mechanical configuration of the EAPdetermines the EAP actuator and its capabilities for motion. The EAP maybe formed into long stands and wrapped around a single centralelectrode. A flexible exterior outer sleeve forms the other electrodefor the actuator as well as contains the ionic fluid necessary for thefunction of the device. In this configuration when the electrical fieldis applied to the electrodes, the strands of EAP shorten. Thisconfiguration of the EAP actuator is called a fiber EAP actuator.Likewise, the laminate configuration may be placed in numerous layers oneither side of a flexible plate or merely in layers on itself toincrease its capabilities. Typical fiber structures have an effectivestrain of 2-4% where the typical laminate version achieves 20-30%utilizing much higher voltages.

In FIG. 2, a laminate EAP composite 100 is depicted as being formed froma positive plate electrode layer 1302 attached to an EAP layer 104,which in turn is attached to an ionic cell layer 106, which in turn isattached to a negative plate electrode layer 108. In FIG. 3, a pluralityof five laminate EAP composites 100 are affixed in a stack by adhesivelayers 110 therebetween to form an EAP plate actuator 120. It should beappreciated that opposing EAP actuators 120 may be formed that canselectively bend in either direction. For example, the laminate EAPcomposite 100 may be differentially activated such that layers on oneside either expand or contract, depending on the configuration of theEAP, thus effecting bending relative to a nonactivated layer. As anotherexample, a non-EAP substrate such as spring steel, resin or polymer isattached to the laminate EAP composite 100. Thus, a laminate EAPcomposite 100 configured to elongate would cause bending of the non-EAPsubstrate away from the laminate EAP composite 100. A laminate EAPcomposite 100 configured to contract would cause bending of the non-EAPsubstrate toward the laminate EAP composite. Having laminate EAPcomposite 100 on both sides of the non-EAP substrate may be used todifferentially effect bending in either direction.

In FIGS. 4-5, a contracting EAP fiber actuator 140 includes alongitudinal platinum cathode wire 142 that passes through an insulativepolymer proximal end cap 144 through an elongate cylindrical cavity 146formed within a plastic cylinder wall 148 that is conductively doped toserve as a positive anode. A distal end of the platinum cathode wire 142is embedded into an insulative polymer distal end cap 150. A pluralityof contracting polymer fibers 152 are arranged parallel with andsurrounding the cathode wire 142 and have their ends embedded intorespective end caps 144, 150. The plastic cylinder wall 148 isperipherally attached around respective end caps 144, 150 to enclose thecylindrical cavity 146 to seal in ionic fluid or gel 154 that fills thespace between contracting polymer fibers 152 and cathode wire 142. Whena voltage is applied across the plastic cylinder wall (anode) 148 andcathode wire 142, ionic fluid enters the contracting polymer fibers 152,causing their outer diameter to swell with a corresponding contractionin length, thereby drawing the end caps 144, 150 toward one another.

EAP Actuated Articulation Joint.

In FIGS. 6-13, a surgical severing and stapling instrument 200 includesan EAP actuated articulation joint 202 that is formed in its elongateshaft 204 proximate to the end effector, which is illustrated by thesurgical stapling and severing assembly 12 that advantageously respondsto separate closure and firing motions that are transferredlongitudinally by the elongate shaft 204. The EAP actuated articulationjoint 202 advantageously adds the desirable clinical flexibility ofarticulating the staple applying assembly 12.

In the illustrative version of FIGS. 6-13, the EAP actuated articulationjoint 202 is more particularly a flexible closure and pivoting framearticulation joint 210, which in FIG. 6 is shown to include a flexibleclosure sleeve assembly 212 having a proximal closure tube 214 anddistal closure ring 216 connected by a flexible closure tube 218. Leftand right longitudinal rows of vertical slits 220, 222 formed in theflexible closure tube 218 allow flexing to the right or to the left forarticulation, yet an uninterrupted top longitudinal band 224 transfers alongitudinal closure motion, regardless of the amount of such flexing.It should be appreciated that an identical uninterrupted bottomlongitudinal band runs along the bottom of the flexible closure tube 218(not shown) and is opposite to and cooperates with the top longitudinalband 224 in transferring this motion. In particular, a top portion ofthe distal closure ring 216 includes a horseshoe aperture 226 thatengages an anvil closure feature 228 of the anvil 22. In FIG. 7, theanvil 22 includes laterally projecting pivot pins 230 at its proximalend that pivotally engage pivot apertures 232 formed near the proximalend of the elongate channel 18 (FIGS. 7-8). The slightly more distalanvil closure feature 228 thus imparts a closing motion when theflexible closure sleeve assembly 212 moves distally and imparts anopening motion when moving proximally. The flexible closure tube 218 maybend along the length of the left and right longitudinal rows ofvertical slits 220, 222, thus accommodating an encompassed single pivotframe assembly 234 of the flexible closure and pivoting framearticulation joint 210 when articulated.

With particular reference to FIGS. 7-9, the single pivot frame assembly234 includes a proximal frame ground 236 with distally projecting topand bottom pivot tabs 238, 240, each having a respective top and bottompivot pin hole 242, 244. Corresponding top and bottom pivot tangs 246,248 projecting proximally from a distal frame ground 250, each tang 246,248 with respective top and bottom pivot pin holes 252, 254, pivotallyengage the proximal frame ground 236. In particular, the verticallyaligned top pivot pin holes 242, 252 and bottom pivot pin holes 244, 254are respectively engaged by top and bottom frame pivot pins 256, 258(FIG. 10).

In FIG. 8, an implement portion 260 of the surgical instrument 200,formed by the elongate shaft 16 and staple applying assembly 12, furtherincludes a firing bar 270 that longitudinally translates through theproximal frame ground 218, through the flexible closure and pivotingframe articulation joint 210, and through a firing slot 272 in thedistal frame ground 250 into the staple applying assembly 12. Distal andproximal square apertures 274, 276 formed on top of the distal frameground 250 define a clip bar 278 therebetween that receives a top arm280 of a clip spring 282 whose lower, distally extended arm 284 assertsa downward pressure on a raised portion 286 along an upper portion ofthe firing bar 270 corresponding to the empty/missing cartridge lockoutportion of firing travel.

With particular reference to FIG. 8, a distally projecting end of thefiring bar 270 is attached to an E-beam 288 that assists in spacing theanvil 22 from the staple cartridge 20, severs tissue, and actuates thestaple cartridge 20. The staple cartridge 20 includes a molded cartridgebody 290 that holds a plurality of staples resting upon staple drivers292 within respective upwardly open staple apertures 294. A wedge sled296 is driven distally by the E-beam 28 21′8, sliding upon a cartridgetray 298 that holds together the various components of the replaceablestaple cartridge 20. The wedge sled 296 upwardly cams the staple drivers292 to force out the staples into deforming contact with the anvil 22while a cutting surface 300 of the E-beam 288 severs clamped tissue. Itshould be appreciated that upper pins 302 of the E-beam 288 engage theanvil 22 during firing while middle pins 304 and a bottom foot 306engage respective top and bottom surfaces of a longitudinal slot 308formed in the elongate channel 18, with a corresponding longitudinalopening 310 in the cartridge tray 298 and a rearwardly open verticalslot 312 in the cartridge body 290. Thereafter, the firing bar 270 isretracted proximally, retracting as well the E-beam 288, allowing theanvil 22 to be opened to release the two stapled and severed tissueportions (not shown).

The staple applying assembly 12 is described in greater detail inco-pending and commonly-owned U.S. patent application Ser. No.10/955,042, “ARTICULATING SURGICAL STAPLING INSTRUMENT INCORPORATING ATWO-PIECE E-BEAM FIRING MECHANISM” to Frederick E. Shelton IV, et al.,filed 30 Sep. 2004, the disclosure of which is hereby incorporated byreference in its entirety.

With particular reference to FIGS. 9-13, an EAP actuator system 400advantageously actuates the single pivot frame assembly 234 in responseto an electrical articulation signal (not shown) received from thehandle 14. In the illustrative version of FIGS. 7-13, top left and topright EAP fiber actuators 402, 404 attach horizontally to each lateralside of a top distally projecting moment arm 406 attached to the toppivot tab 238. The outer ends of the top left and top right EAP fiberactuators 402, 404 are attached to respective upper left and rightlateral attachment points 406, 408 of an inner diameter 410 of thedistal frame ground 250. Similarly, bottom left and bottom right EAPfiber actuators 412, 414 attach horizontally to each lateral side of abottom distally projecting moment arm 416 attached to the top pivot tab238. The outer ends of the bottom left and bottom right EAP fiberactuators 412, 414 are attached to respective lower left and rightlateral attachment points 418, 420 of the inner diameter 410 of thedistal frame ground 250. The attachments points 406, 408, 418, 420 areshown to pass through the distal frame ground 250 in FIG. 12 with theleft attachment points 406, 418 visible on the exterior of the distalframe ground 250 in FIG. 9. Activating one pair of EAP actuators, suchas in FIG. 13, and in particular reference to the upper and lower rightEAP fiber actuators 404, 414, causes them to contract, drawing the upperand lower moment arms 406, 416 toward the right side of the distal frameground 250, thereby stretching the upper and lower EAP fiber actuators402, 412, collapsing the left longitudinal row of vertical slits 220,and expanding the right longitudinal row of vertical slits 222.

In FIGS. 14-18, a surgical severing and stapling instrument 500 includesan alternative EAP actuated articulation joint 502 that includes adouble pivot closure sleeve assembly 504 (FIG. 14-15) and a single pivotframe assembly 506 (FIG. 15-18). In FIG. 14, the staple applyingassembly 12 is depicted with the replaceable staple cartridge 20 removedand the anvil 22 open. Thus, the double pivot closure sleeve assembly504 is at its proximal position with its distal pivoting axis alignedwith a pivoting axis of the frame assembly 506. It should be appreciatedthat with the closure sleeve assembly 504 moved distally to close theanvil 22, a proximal pivot axis of the closure sleeve assembly 504 alsopivots in order to translate over an articulated frame assembly 506.

With particular reference to FIG. 15, the double pivot closure sleeveassembly 504 includes a proximal closure tube 510 whose distal end iskeyed to attach to a proximal closure ring 512 having upper and lowerdistally projecting tangs 514, 516. A distal closure tube 518, whichincludes a horseshoe aperture 520 to engage the anvil closure feature228 on the anvil 22, is proximally pinned to a distal closure ring 522having upper and lower proximally projecting tangs 524, 526. An upperdouble pivot link 528 includes upwardly projecting distal and proximalpivot pins 530, 532 that engage respectively an upper distal pin hole534 in the upper proximally projecting tang 524 and an upper proximalpin hole 536 in the upper distally projecting tang 514. A lower doublepivot link 538 includes downwardly projecting distal and proximal pivotpins 540, 542 that engage respectively a lower distal pin hole 544 inthe lower proximally projecting tang 526 and a lower proximal pin hole546 in the lower distally projecting tang 516.

With particular reference to FIGS. 15-18, the single pivot frameassembly 506 includes a proximal frame ground 550 whose distal endincludes a pivot pin hole 552 centered and proximal to a distally openpivot recess 554 defined between left and right moment arms 556, 558. Adog bone link 560 includes a proximal pin 562 that upwardly engages thepivot pin hole 552 in the proximal frame ground 550 and a center bar 564that pivots between the left and right moment arms 556, 558. A distalpin 566 of the dog bone link 560 is rigidly attached into a lowerproximal bore 568 in a distal frame ground 570 having distal lateralguides 572 that engage proximal guides 574 in the elongate channel 18.

An EAP actuation system 580 includes left and right EAP stack actuators582, 584 that selectively expand to assert an articulation force on thecenter bar 564 of the dog bone link 560, which passively compresses theother EAP stack actuator. In FIG. 18, the right EAP stack actuator 582has expanded, pivoting the dog bone link 560, and thus the stapleapplying assembly 12, to the left and passively compressing the left EAPstack actuator 584.

In FIG. 19, yet another alternative EAP actuated articulation joint 600for a surgical instrument 602 includes a single pivoting frame assembly604 wherein a proximal frame ground 606 is engaged to a distallyprojecting tang 608 from a distal frame ground 610 at a pivot pin 612.The distally projecting tang 608 is recessed on a right lateral side todefine a half teardrop shaped pulley 614 on the right side of the pivotpin 612. Attached to a distal point of the half teardrop shaped pulley614 is a distal end of a contracting EAP fiber actuator 616 that followsthe contour thereof and passes into the proximal frame ground 606. Thecontracting EAP fiber actuator 616 may be sufficiently long so that, foreven a small percentage contraction in a length, a significant rotationmay be achieved. It should be appreciated that a counter rotatingmechanism may be incorporated on a left side of the depicted tang 608 ona similar but reversed mechanism formed on the other side of the EAParticulation joint 600.

Articulation Locking Mechanism for Pivoting Articulation Mechanism.

In FIGS. 20-27, an EAP actuated articulation lock 700 is incorporatedinto a pivoting articulation joint 702 for a surgical instrument 704.For clarity, a single pivoting frame assembly 706 is depicted with aproximal frame ground 708 having distally extended upper and lower pivottabs 710, 712 that are pivotally engaged to proximally directed upperand lower tangs 714, 716 of a distal frame ground 718 that is attachedto an end effector 720. An upper inner hole 722 in the upper pivot tab710 is aligned under an upper outer hole 724 in the upper tang 714,which are pivotally pinned together by upper pivot pin 726. A lowerinner hole 728 in the lower pivot tab 712 is aligned above a lower outerhole 730 in the lower tang 716. Holes 728,712 are pivotally pinnedtogether by a lower pivot pin 732. Upper and lower moment arms 734, 736extend distally respectively from the upper and lower pivot tabs 710,712. The upper moment arm 734 may be urged to the left toward an upperleft attachment point 738 formed in the distal frame ground 718 by agenerally horizontal upper left EAP fiber actuator 740. The upper momentarm 734 may be urged to the right toward an upper right attachment point742 formed in the distal frame ground 718 by a generally horizontalupper right EAP fiber actuator 744. The lower moment arm 736 may beurged to the left toward a lower left attachment point 746 formed in thedistal frame ground 718 by a generally horizontal lower left EAP fiberactuator 748. The lower moment arm 736 may be urged to the right towarda lower right attachment point 750 formed in the distal frame ground 718by a generally horizontal lower right EAP fiber actuator 752.

Closure of the anvil 22 may occur by action of a closure mechanism thatis not shown, such as an EAP actuator that acts upon the anvil pivot.Alternatively, a firing motion may first close the anvil prior tofurther motion effecting stapling and severing. As a furtheralternative, a closure sleeve assembly or other longitudinally coupledmechanism (not shown) may impart a closing motion to the anvil 22.

An upper EAP actuated articulation locking mechanism 800 advantageouslyunlocks the pivoting articulation joint 702 to allow articulatingmovement. The EAP actuated articulation locking mechanism 800 thenrelaxes to a locked state, providing a stable locked position that doesnot require power dissipation, and thus component heating, betweenchanges in an amount of articulation. An upper locking bolt assembly 802is shown in a rectangular upper lock recess 804 formed in the proximalframe ground 708 proximal to and vertically farther from thelongitudinal centerline than the upper pivoting tab 710. A locking bolt806 extends a locking tip 808 out of a distal slot 810, formed in theupper lock recess 804, into engagement in a nearest tooth root 812 of agear segment 814 formed about a proximal surface about the upper pivottang 714 of the distal frame ground 718. The locking bolt 806 proximallyterminates in cross plate 816 that slides longitudinally in therectangular upper lock recess 804 between the urging of a proximallypositioned compression spring 818 and upper left and right EAP stackactuator 820, 822 that may be activated to expand longitudinally,compressing the compression spring 818 as the lock bolt 806 is movedproximally, thereby disengaging the locking tip 808 from the gearsegment 814, allowing the pivoting articulation joint 702 to berepositioned. An upper lock cover 824 closes the upper lock recess 804.

For additional locking support, in FIG. 23, a lower EAP actuatedarticulation locking mechanism 830, that is identical to the upperlocking mechanism 800, acts on the opposite site against lower pivottang 716. It should further be appreciated that a similar lockingmechanism may be incorporated into a distal portion of an elongate shaftrather than a proximal end. Further, a double pivoting coupling mayinclude a lock at each pivot.

In use, an unarticulated end effector 720 and pivoting articulationjoint 702 (FIGS. 20-24) are inserted to a surgical site. With EAPlocking mechanisms 800, 830 typically deenergized, the locking tip 808attached to the proximal frame ground 708 engages the gear segment 814of the distal frame ground 718, locking the single pivot frame assembly706. When desired, EAP stack actuators 820, 822 are energized tolongitudinally lengthen, unlocking the EAP articulation lockingmechanisms 800, 830. While unlocked, the articulation joint 702 may bearticulated, such as by contracting upper and lower right EAP fiberactuators 744, 752 to pivot the end effector 720 to the left (FIG. 25),presenting a different tooth root 812 to the locking tip 808 so thatwhen deenergized the EAP articulation locking mechanism 800 will lock tothe articulation condition of the surgical instrument 704.

In FIGS. 28-29, an alternative EAP articulation system 900 for a singlepivot articulation joint 901 is depicted for use in conjunction with theEAP articulation locking mechanism 800 previously described. Upper andlower pairs of left and right EAP fiber actuators 902, 904, 906, 908 arelengthened by incorporating upper and lower rounded moment arms 910, 912distally respectively on upper and lower pivot tabs 914, 916 of aproximal frame ground 918. An upper left attachment point 920 in adistal frame ground 922 is slightly higher than an upper rightattachment point 924. A lower left attachment point 926 is also slightlyhigher than a lower right attachment point 928, corresponding to theupper and lower left EAP fiber actuators 902, 906 wrapping respectivelyaround a higher portion of the corresponding upper and lower roundedmoment arms 910, 912 than the upper and lower right EAP fiber actuators904, 908 (FIG. 29). Thereby, the lengthened EAP fiber actuators 902-908in combination with the length and contour of the moment arms 910, 912may be selected for a desired performance characteristic.

In FIGS. 30-33, an additional alternative EAP articulation system 1000for a single pivot articulation joint 1001 is depicted for use inconjunction with the EAP articulation locking mechanism 800 previouslydescribed. Instead of EAP fiber actuators that effect articulation,upper and lower pairs of left and right EAP stack actuators 1002, 1004,1006, 1008 respectively oppose and laterally move upper and lowerlongitudinal tracks 1010, 1012. A distally projecting upper moment arm1014 attaches to an upper pivot tab 1016 of a proximal frame ground1018. An upper inwardly directed tip pin 1020 at a distal end of theupper moment arm 1014 longitudinally slidingly engages the upperlongitudinal track 1010, and thus responds to the differentialcontraction and expansion of the upper left and right EAP stackactuators 1002, 1004 that are laterally constrained by a distal frameground 1022. A distally projecting lower moment arm 1024 attaches to anupper pivot tab 1026 of the proximal frame ground 1018. A lower inwardlydirected tip pin 1030 at a distal end of the upper moment arm 1024longitudinally slidingly engages the lower longitudinal track 1012, andthus responds to the differential contraction and expansion of the lowerleft and right EAP stack actuators 1006, 1008 that are laterallyconstrained by the distal frame ground 1022.

In FIGS. 30-31, the EAP articulation locking mechanism 800 is activatedto disengage the locking tip 808 from the gear segment 814 inpreparation for articulation. In FIGS. 32-33, the upper and lower leftEAP stack actuators 1002, 1006 have been energized to expand, laterallymoving rightward the upper and lower longitudinal tracks 1010, 1012,thereby compressing the upper and lower EAP stack actuators 1004, 1008and moving distal frame ground 1022 correspondingly against the reactionforce from the upper and lower inwardly directed tip pins 1020, 1030,which in the illustrative articulation is to the left.

Surgical Instrument with EAP Actuated Flexneck Articulation Joint.

In FIG. 34, a surgical instrument 1200 advantageously incorporates anEAP actuated articulation joint 1202 that is integral to an articulatingframe assembly 1204 of an elongate shaft 1206 that transfers separateclosure and firing motions from a handle 1208 to an end effector 1210,depicted as a staple applying assembly 1212 having a closeable anvil1214 that is pivotally attached to an elongate channel 1216 that holds areplaceable staple cartridge 1218. The handle 1208 includes a closuretrigger 1220 that is squeezed proximally toward a pistol grip 1222 toeffect closure of the anvil 1214. It should be appreciated that aclosure sleeve assembly 1223 or other closure means (e.g., EAP actuatedanvil, internal longitudinally translating member, etc.) that is notshown acts upon an anvil closure feature 1224 to effect opening andclosing of the anvil 1214. Once closed and clamped, a more distal firingtrigger 1226 is squeezed toward the pistol grip 1222 to effect firing ofa firing member 1228 longitudinally down the elongate shaft 1206 tocause severing of tissue and stapling of the severed ends. Once thefiring trigger 1226 is released, a closure release button 1230 isdepressed along with a slight depression of the closure trigger 1220 torelease clamping components followed by release of the closure trigger1220 to open the anvil 1214 and allow release of the stapled and severedtissue. A rotation knob 1232 allows selective rotation about alongitudinal axis of the elongate shaft 1206.

The articulating frame assembly 1204 includes a proximal frame ground1240 proximally and rotatably attached to the handle 1208 and distallyattached to an articulating frame ground 1242 that in turn is attachedto a distal frame ground 1244 that supports the end effector 1210. Anarticulation control 1246 on the handle 1208 advantageously allowsselection of articulation of the articulating frame ground 1242 byactivating appropriate electrical signals thereto, such as depicted inFIG. 35 when a leftward articulation has been selected by articulationcontrol 1246. It should be appreciated that the articulation control1246 may advantageously include manual and/or automatic disengagement ofan articulation lock for the articulating frame ground 1242.

In FIGS. 36-39, the articulating frame ground 1242 incorporates an EAPactuating system 1300 that uses left and right EAP plate actuators 1302,1304 that pass through respective left and rectangular actuator recesses1306, 1308 (FIGS. 38-39) in each lateral side of a generally cylindricalresilient frame body 1310. A rectangular knife slot 1312 is formed inthe resilient frame body 1310 aligned between the left and rightrectangular actuator recesses 1306, 1308 for guiding a firing bar 1314that is a distal portion of the firing member 1228.

Continuous top and bottom longitudinal bands 1320 (FIGS. 36-37) of theresilient frame body 1310 maintain a longitudinal amount of travel forthe firing bar 1314 when the articulating frame ground 1242 is eitherstraight or articulated. The resilient frame body 1310 is advantageouslyformed from a homogenous material that does not significantly compressalong its longitudinal axis. Left and right pluralities oflongitudinally aligned vertical recesses 1322, 1324 intersectrespectively with the left and right EAP actuator recesses 1306, 1308.Each vertical recess 1322, 1324 includes a rectangular through hole 1326that passes from top to bottom through the resilient frame body 1310parallel with and laterally offset from both the rectangular knife slot1312 and the appropriate one of either the left or right rectangularactuator recess 1306, 1308. Each rectangular through hole 1326communicates laterally with a narrowed lateral gap 1328. Adjacentvertical recesses 1322, 1324 define therebetween a rib 1330 that has anarrow inner wall 1332, which allows lateral bending of the continuoustop and bottom longitudinal bands 1320, and a thicker curved outer slice1334 that supports the respective one of the EAP plate actuators 1302,1304 and limits the amount of articulation that may be achieved in thatdirection before the narrowed lateral gaps 1328 collapse fully as one orboth EAP plate actuators 1302, 1304 are activated to bend in a selecteddirection. In FIG. 37, for instance, the left EAP plate actuator 1302 isactivated to actuate to the left with the right EAP plate actuator 1304stretching in response. It should be appreciated that the left and rightEAP plate actuators 1302, 1304 may alternatively contract or expand whenelectrically activated to create a pull or a push respectively withinthe left and right rectangular actuator recesses 1306, 1308.

In FIGS. 38-39, the articulating frame ground 1242 advantageouslyincludes an EAP articulation locking mechanism 1350 that selectivelyholds the resilient frame body 1310 in an articulated left or anarticulated right condition. To that end, a left locking passage 1352 isdefined passing through the left plurality of rectangular through holes1326 proximate to their leftmost outer portion, allowing a left ridgedEAP locking strip 1354 to pass therethrough. Similarly, a right lockingpassage 1356 is defined as passing through the right plurality ofrectangular through holes 1326 proximate to their rightmost outerportion, allowing placement of a right ridged EAP locking strip 1358.Along their respective outermost surface 1360 of both the left and rightridged EAP locking strips 1354, 1358, a plurality of longitudinallyspaced vertical blocking ridges 1362 are longitudinally spaced and sizedto define, in conjunction with the geometry of the ribs 1330 to lock ata desired articulation amount. In particular, when the flexible frameground 1242 articulates toward the opposite side of a respective ridgedEAP locking strip 1354, 1358, the ribs 1330 on that side arc away fromone another, as depicted in FIG. 38 in articulating to the left. Oncethe ribs 1330 have reached a spacing sufficient for locking (i.e., widerthan the longitudinal width of the vertical blocking ridges 1362, theright ridged EAP locking strip 1358 is biased outwardly to snap itsridges 1362 between adjacent thickened thicker curved outer slices 1334of adjacent ribs 1330. Activating the right ridged EAP locking strip1358 causes contraction that unlocks the right ridged EAP locking strip1358. In FIG. 39, lateral upper and lower guide pins 1370, 1372 thatpass above and below the rectangular knife slot 1312 preserve lateralalignment.

In FIG. 40, the articulating frame ground 1242 incorporates an EAPactuating system 1400 that uses a plurality of left and right EAP ribspreader plate actuators 1402 that each reside between an opposing pairof distally and proximally open rectangular recesses of a resilientframe body 1408. Each opposing pair of distally and proximally openrectangular actuator recesses 1404, 1406 respectively are formed in anadjacent pair (proximal/distal) of laterally defined ribs 1410. Each rib1410 includes a vertical slot 1412 that is open outwardly laterallyalong its height with a wider rectangular through hole 1414 moreinwardly positioned that narrows into an outer vertical slot 1416. Eachrib 1410 thus includes a thin inner wall 1418 that connects to upper andlower longitudinal continuous bands 1420. A rectangular knife slot 1422is formed laterally along the longitudinal centerline. Left and rightridged EAP locking strips 1354, 1358, as described above, advantageouslyrelax to an expanded curved shape on the expanded side of thearticulating frame ground 1242 to lock, with longitudinal alignmentmaintained by lateral guide pins 1370.

In FIGS. 41-42, the articulating frame ground 1242 incorporates afurther alternative EAP actuating system 1500 into a resilient framebody 1502 that includes longitudinally aligned EAP fiber actuators 1504arranged in left and right vertical stacks 1506, 1508 that pass througha respectively left and right plurality of lateral ribs 1510, eachhaving a thin inner vertical wall 1512 that connects to continuouslongitudinal top and bottom bands 1514 to facilitate lateral bendingthereof. Each rib 1510 widens laterally to a thick outer slice 1516 thatis dimensioned for the limitation on articulation to that side. Eachthick outer slice 1516 includes a vertical aligned longitudinal throughhole 1518 for allowing the EAP fiber actuators 1504 to pass through.Distal and proximal lateral covers 1520, 1522 longitudinally flank theribs 1510 to cover respective termination ends of the EAP fiberactuators 1504. A laterally centered knife slot 1524 is formed in theresilient frame body 1502 for the firing bar 1314. Contracting aselected vertical stack 1506, 1508 of EAP fiber actuators 1504 causesarticulation to that side with the nonactuated vertical stack 1506, 1508passively elongating in response thereto.

EAP Support Plates for Firing Bar.

With regard to FIGS. 43-54, lateral symmetry prevails for variousversions of pairs of support plate that support a firing bar in anarticulation joint. In addition, it is contemplated that applicationsconsistent with the present invention may include either end as theproximal or distal end of a depicted articulation joint for those thatare not also longitudinally symmetric. Thus, designation of onelaterally symmetric component with a suffix “a” and the designation of amirror image component with a suffix “b” is not intended to imply eitherright or left.

In FIG. 43, an articulation joint 2000 for a surgical instrument 2002includes a pair of EAP support plates 2004, 2006 that laterally supporta firing bar 2008 to minimize binding and buckling when articulated.Each support plate 2004, 2006 includes a respective structural member2010 a, 2010 b (e.g., rigid polymer, metal) that includes a laterallywidened end 2012 a, 2012 b that is captured within a correspondinglysized recess 2014 a, 2014 b in a first frame ground 2016 and a straightend 2018 a, 2018 b that is slidingly received within a second frameground 2020. A longitudinally expansive EAP laminate 2022 a, 2022 bcovers an internal surface of each support plate 2004, 2006.

In FIG. 44, the articulation joint 2000 is articulated to one lateralside, causing the firing bar 2008 to overshoot an articulatedlongitudinal axis 2024 and come into contact with support plate 2006.Lateral support therefrom prevents a blow out of the firing bar 2008 outof the articulation joint 2000 and/or allows fabrication of a moreflexible firing bar 2008 with thus reduced force to articulate. Inaddition, the EAP laminates 2022 a, 2022 b on each support plate 2004,2006 are activated as necessary to control the amount of curvature ofboth to preserve a desired spacing therebetween for the firing bar 2008.The straight ends 2018 a, 2018 b slide in the second frame groundportion 2020 to accommodate the reduced travel required of the innersupport plate 2004 as compared to the outer support plate 2006. The EAPlaminate 2022 b may further provide cushioning and low surface frictioncharacteristics that assist in laterally guiding the firing bar 2008.

In FIG. 45, an alternative articulation joint 2100 for a surgicalinstrument 2102 includes a pair of EAP support plates 2104, 2106 thatlaterally support a firing bar 2108 to minimize binding and bucklingwhen articulated. Each support plate 2104, 2106 includes, respectively,a structural member 2110 a, 211 b (e.g., rigid polymer, metal) thatincludes a laterally widened end 2112 a, 2112 b that is captured withina correspondingly sized recess 2114 a, 2114 b in a first frame ground2116 and a straight end 2118 a, 2118 b that is slidingly received withina second frame ground 2120. A longitudinally expansive EAP laminate 2122a, 2122 b covers an outer surface of each support plate 2104, 2106. Thearticulation joint 2100 is articulated to one lateral side, causing thefiring bar 2108 to overshoot an articulated longitudinal axis 2124 andcome into contact with support plate 2106. Lateral support therefromprevents a blow out of the firing bar 2108 out of the articulation joint2100 and/or allows fabrication of a more flexible firing bar 2108 withthus reduced force to articulate. In addition, the EAP laminates 2122 a,2122 b on each support plate 2104, 2106 respectively are activated asnecessary to control the amount of curvature of both to preserve adesired spacing therebetween for the firing bar 2108. The straight ends2118 a, 2118 b slide in the second frame ground portion 2120 toaccommodate the reduced travel required of the inner support plate 2104as compared to the outer support plate 2106. Placement of the EAPlaminates 2122 a, 2122 b away from contact with the firing bar 2108 mayhave advantages such as reducing wear to the EAP laminates 2122 a, 2122b.

In FIG. 46, an additional alternative articulation joint 2200 for asurgical instrument 2202 includes a pair of EAP support plates 2204,2206 that laterally support a firing bar 2208 to minimize binding andbuckling when articulated. Each support plate 2204, 2206 includes arespective structural member 2210 (e.g., metal) that includes a firstoutwardly tabbed end 2212 a, 2212 b that is constrained andlongitudinally free floating within a first inwardly open recess 2214 a,2214 b in a first frame ground 2216 and a second outwardly tabbed end2218 a, 2218 b that is constrained and longitudinally free floatingwithin a second inwardly open recess 2220 a, 2220 b of a second frameground 2222. A longitudinally expansive EAP laminate 2224 a, 2224 bcovers an inner surface of each support plate 2204, 2206.

In FIG. 47, yet an additional alternative articulation joint 2300 for asurgical instrument 2302 includes a pair of EAP support plates 2304,2306 that laterally support a firing bar 2308 to minimize binding andbuckling when articulated. Each support plate 2304, 2306 includes arespective structural member 2310 a, 2310 b (e.g., metal) that includesa first outwardly tabbed end 2312 a, 2312 b that is fixed with aninwardly open slot 2314 a, 2314 b in a first frame ground 2316 and asecond outwardly tabbed end 2318 a, 2318 b that is constrained andlongitudinally free floating within an inwardly open recess 2320 a, 2320b of a second frame ground 2322. A longitudinally expansive EAP laminate2324 a, 2324 b covers an inner surface of each support plate 2304, 2306.A pair of compression springs 2326 a, 2328 a are longitudinally alignedwithin the inwardly open recess 2320 a biasing the second outwardlytabbed end 2318 a of support plate 2304 to a neutral position therein.Similarly, a pair of compression springs 2326 b, 2328 b arelongitudinally aligned within the inwardly open recess 2320 b biasingthe second outwardly tabbed end 2318 b of support plate 2306 to aneutral position therein.

In FIG. 48, yet a further alternative articulation joint 2400 for asurgical instrument 2402 includes a pair of EAP support plates 2404,2406 that laterally support a firing bar 2408 to minimize binding andbuckling when articulated. Each support plate 2404, 2406 includes,respectively, a structural member 2410 a, 2410 b (e.g., metal) thatincludes a first outwardly tabbed end 2412 a, 2412 b that is constrainedbut longitudinally free floating with a first inwardly open recess 2414a, 2414 b in a first frame ground 2416 a, 2416 b and a second outwardlytabbed end 2418 a, 2418 b that is constrained and longitudinally freefloating within a second inwardly open recess 2420 a, 2420 b of a secondframe ground 2422. A longitudinally expansive EAP laminate 2424 a, 2424b covers an inner surface of each support plate 2404, 2406. A respectivepair of compression springs 2426 a-2428 a, 2426 b-2428 b arelongitudinally aligned respectively within the first inwardly openrecess 2414 a, 2414 b biasing the first outwardly tabbed end 2412 a,2412 b of each support plate 2404, 2406 to a neutral position therein.Another respective pair of compression springs 2430 a-2432 a, 2430b-2432 b are longitudinally aligned within the second inwardly openrecess 2420 a, 2420 b biasing the second outwardly tabbed end 2418 a,2418 b of each support plate 2404, 2406 to a neutral position therein.

In FIGS. 49-52, yet a further alternative articulation joint 2500 for asurgical instrument 2502 incorporates EAP support plates 2504, 2506 thatreside on each lateral side of a firing bar 2508 in a knife slot 2510 ofa resilient frame body 2512 of an articulating frame ground 2514proximally coupled to a proximal frame ground 2516 and distally coupledto a distal frame ground 2518. A left EAP plate actuator 2520 passesthrough a left plurality of lateral ribs 2522 formed in the resilientframe body 2512. A right EAP plate actuator 2524 passes through a rightplurality of lateral ribs 2526. Each EAP plate actuator 2520, 2524 whichextends proximally into the proximal frame ground 2516, includes,respectively, an outer EAP laminate layer 2528 a, 2528 b attached to aninner plate 2530 a, 2530 b and is configured to actuate whenelectrically energized to bend the distal frame round 2518 toward theother side. The resilient frame body 2512 includes proximal inwardlyopen recesses 2532 that grip respective proximal, outwardly curved ends2534 a, 2534 b of each support plate 2504, 2506. Distal straight ends2536 a, 2536 b of each support plate 2504, 2506 are allowed to slide outof the knife slot 2510 to adjust for changes in travel for articulation,as depicted in FIG. 51.

In FIG. 53, yet another alternative articulation joint 2600 for asurgical instrument 2602 includes a pair of EAP support plates 2604,2606 that laterally support a firing bar 2608 to minimize binding andbuckling when articulated. Each support plate 2604, 2606 includes arespective structural member 2610 (e.g., metal, resin, polymer) thatincludes a first outwardly tabbed end 2612 that is fixed with arespective right and left inwardly open slot 2614 a, 2614 b in a firstframe ground 2616 and a second outwardly tabbed end 2618 a, 2618 b thatis respectively constrained and longitudinally free floating within aninwardly open recess 2620 a, 2620 b of a second frame ground 2622.

An outer longitudinally expansive EAP laminate 2624 a, 2624 b ispositioned in an outer portion of the respective inwardly open recess2620 a, 2620 b against the second outwardly tabbed end 2618 a, 2618 b.An inner longitudinally expansive EAP laminate 2625 a, 2625 b ispositioned in an inner portion of the inwardly open recess 2620 a, 2620b against a respective opposite side of the second outwardly tabbed end2618 a, 2618 b. Thus, activating one of the outer longitudinal expansiveEAP laminate 2624 a, 2624 b effectively lengthens the respective supportplate 2604, 2606. Conversely, activating one of the inner longitudinalexpansive EAP laminate 2625 a, 2625 b effectively shortens therespective support plate 2604, 2606.

In FIG. 54, yet a further alternative articulation joint 2700 for asurgical instrument 2702 includes a pair of EAP support plates 2704,2706 that laterally support a firing bar 2708 to minimize binding andbuckling when articulated. Each support plate 2704, 2706 includes arespective structural member 2710 a, 2710 b (e.g., metal) that includesa first outwardly tabbed end 2712 a, 2712 b that is constrained butlongitudinally free floating with a first inwardly open recess 2714 a,2714 b in a first frame ground 2716 and a second outwardly tabbed end2718 a, 2718 b that is constrained and longitudinally free floatingwithin a second inwardly open recess 2720 a, 2720 b of a second frameground 2722.

An outer longitudinally expansive EAP laminate 2724 a, 2724 b ispositioned in an outer portion of the respective second inwardly openrecess 2720 a, 2720 b against the second outwardly tabbed end 2718 a,2718 b. An inner longitudinally expansive EAP laminate 2725 a, 2725 b ispositioned in an inner portion of the second inwardly open recess 2720a, 2720 b against a respective opposite side of the second outwardlytabbed end 2618 a, 2618 b. To effectively double the effectivelengthening or shortening of the support plate 2704, 2706, another outerlongitudinally expansive EAP laminate 2734 a, 2734 b is positioned in anouter portion of the respective first inwardly open recess 2714 a, 2714b against the first outwardly tabbed end 2712 a, 2712 b. Another innerlongitudinally expansive EAP laminate 2735 a, 2735 b is positioned in aninner portion of the first inwardly open recess 2720 a, 2720 b against arespective opposite side of the first outwardly tabbed end 2612 a, 2612b. Thus, activating a first lateral pair of the outer longitudinalexpansive EAP laminate 2724 a, 2734 a effectively lengthens the supportplate 2704 and activating the second lateral pair of the outerlongitudinal expansive EAP laminate 2724 b, 2734 b effectively lengthensthe support plate 2706. Conversely, activating a first lateral pair ofthe inner longitudinal expansive EAP laminate 2726 a, 2736 a effectivelyshortens the support plate 2704 and activating the second lateral pairof the inner longitudinal expansive EAP laminate 2726 b, 2736 beffectively shortens the support plate 2706.

In each of these versions, articulation support control circuitry mayadvantageously activate one or both EAP support plates to effect theirlongitudinal length and/or to effect their degree of longitudinaldeflection or bending. For example, activation of the EAP support platesmay occur to effect articulation of the joint and to support the firingbar, and thus remain active. As another example, actuation of thearticulation joint may be performed separately by mechanical orelectrical means with articulation support control circuitry activatedwhile actuated or immediately proceeding firing (e.g., once closing ofthe end effector is sensed or commanded).

While the present invention has been illustrated by description ofseveral embodiments and while the illustrative embodiments have beendescribed in considerable detail, it is not the intention of theapplicant to restrict or in any way limit the scope of the appendedclaims to such detail. Additional advantages and modifications mayreadily appear to those skilled in the art.

For example, while a hand manipulated surgical instrument is depicted inillustrative versions, it should be appreciated that aspects of thepresent invention may be incorporated into robotically positioned andcontrolled instruments. Thus a handle portion may comprise an externalportion that is stabilized in a fixture.

1. A surgical instrument, comprising: a handle portion comprising:articulation control circuitry operably configured to produce anarticulation support signal, a firing mechanism including alongitudinally translating firing bar; an elongate shaft attached to thehandle and including a firing bar guide slot encompassing the firingbar; and an end effector distally attached to the elongate shaft andactuated by a distal end of the firing bar; an articulation jointcoupling the elongate shaft to the end effector and in communicationwith the articulation support signal through the elongate shaft; and apair of electroactive polymer support members positioned in thearticulation joint on each lateral side of the firing bar responsive tothe articulation support signal to dimensionally adjust in compensationfor articulating to a selected lateral side.
 2. The surgical instrumentof claim 1, wherein a selected one of the pair of electroactive polymersupport members on an inside of an articulation movement contracts inresponse to the articulation support signal.
 3. The surgical instrumentof claim 1, wherein a selected one of the pair of electroactive polymersupport members on an outside of an articulation movement elongates inresponse to the articulation support signal.
 4. The surgical instrumentof claim 1, wherein the electroactive polymer support members eachcomprise an electroactive polymer plate actuator operably configured tolaterally deflect in response to the articulation support signal.
 5. Thesurgical instrument of claim 4, wherein a selected one of the proximalportion and the distal portion of the articulation joint include a framerecess communicating with the firing bar guide slot, each electroactivepolymer plate actuator comprising a rigid substrate having an outwardlydeflected end received in the frame recess and comprising anelectroactive polymer actuator attached to one side of the rigidsubstrate to effect bending in response to the articulation supportsignal.
 6. The surgical instrument of claim 5, further comprising aresilient member inserted in longitudinal opposition between theoutwardly deflected end of the rigid substrate and a wall of the framerecess.
 7. The surgical instrument of claim of claim 5, wherein theelectroactive polymer actuator is attached on an inside surface of therigid substrate proximate to the firing bar.
 8. The surgical instrumentof claim 5, wherein an inner surface of the rigid substrate is proximateto the firing bar and wherein the electroactive polymer actuator isattached on an outer surface of the rigid substrate.
 9. The surgicalinstrument of claim 1, wherein the articulation joint comprises aproximal portion attached to the elongate shaft and a distal portionattached to the end effector, the proximal portion attached forarticulating movement to the distal portion, each electroactive polymeractuator attached respectively to the proximal portion and distalportion and operatively configured to effect articulation in response tothe articulation support signal.
 10. The surgical instrument of claim 9,wherein the articulation joint comprises the proximal portion pivotallyattached to the distal portion.
 11. The surgical instrument of claim 9,wherein the articulation joint comprises an upper band and a lower bandeach formed of a flexible and longitudinally incompressible materialattached between the proximal and distal portions and a plurality ofleft vertical ribs and a plurality of right vertical ribs, each ribconnected on a respective lateral side between the upper and lowerbands.
 12. The surgical instrument of claim 9, wherein a selected one ofthe pair of electroactive polymer support members on an inside of anarticulation movement contracts in response to the articulation supportsignal.
 13. The surgical instrument of claim 9, wherein a selected oneof the pair of electroactive polymer support members on an outside of anarticulation movement elongates in response to the articulation supportsignal.
 14. The surgical instrument of claim 9, wherein theelectroactive polymer support members each comprise an electroactivepolymer plate actuator operably configured to laterally deflect inresponse to the articulation support signal.
 15. The surgical instrumentof claim 9, wherein each of the electroactive polymer support memberscomprise a structural member having a longitudinal portion and anoutwardly bent tab at each end constrained respectively within theproximal portion and the distal portion of the articulation joint, andfurther comprise an inner and outer electroactive polymer actuator, eachconfigured for longitudinal expansion positioned on longitudinallyopposite sides of a selected one of the outwardly bent tabs wherein therespective portion of the articulation joint includes an inwardly openrecess that receives the inner and outer electroactive polymer actuatorsand the selected one of the outwardly bent tabs.
 16. The surgicalinstrument of claim 15, wherein each of the electroactive polymersupport members further comprise a second pair of inner and outerelectroactive polymer actuators each configured for longitudinalexpansion positioned on longitudinally opposite sides of the other oneof the outwardly bent tabs wherein the respective portion of thearticulation joint includes an inwardly open recess that receives thesecond pair of inner and outer electroactive polymer actuators and theother one of the outwardly bent tabs, the articulation control circuitryoperatively configured to activate both outer electroactive polymeractuators of a selected electroactive polymer support member to effectlengthening and to activate both inner electroactive polymer actuatorsto effect shortening.
 17. A surgical instrument, comprising: a handleportion comprising an articulation control circuitry operably configuredto produce an articulation support signal; an elongate shaft attached tothe handle portion; and an end effector distally attached to theelongate shaft; an articulation joint coupling the elongate shaft to theend effector and in communication with the articulation support signalthrough the elongate shaft; and a pair of electroactive polymer supportmembers positioned on lateral sides of the articulation joint, eachhaving one end longitudinally constrained therein and the otherslidingly received, aligned with and offset from a longitudinal axis ofthe elongate shaft, each electroactive polymer support member responsiveto the articulation support signal to bend laterally.
 18. A surgicalinstrument, comprising: a handle portion comprising an articulationcontrol circuitry operably configured to produce an articulation supportsignal; an elongate shaft attached to the handle portion; and an endeffector distally attached to the elongate shaft; an articulation jointcoupling the elongate shaft to the end effector and in communicationwith the articulation support signal through the elongate shaft; and apair of electroactive polymer support members positioned on lateralsides of the articulation joint, each having both ends longitudinallyconstrained therein, aligned with and offset from a longitudinal axis ofthe elongate shaft, each electroactive polymer support member responsiveto the articulation support signal to selectively lengthen and shorten.